TwinCAT 3 Development Guide for APR System

Version: APR-2026.01 | TwinCAT: 3.1 Build 4024.65

Development environment setup and best practices for HIWIN LMSA13L control.

Overview

This skill covers TwinCAT 3 development for the APR dual-axis linear motor system, including version selection, project setup, extension libraries, and ST programming patterns.

Version Strategy

Windows 11 Compatibility

For local simulation on Windows 11:

• •Use 4024.65 or earlier (4024.64, 4024.47)
• •Versions 4024.66+ have poor Win11 local support
• •Install with Administrator + Complete option

Installation Notes

✓ TC31-FULL-Setup.3.1.4024.65.exe (Administrator + Complete)
✗ Do NOT install XAR/ADS/RM separately after Full installation

After installation, run as Administrator:

"C:\TwinCAT\3.1\System\win8settick.bat"

Project Setup

Recommended Project Type

In Visual Studio: TwinCAT XAE Project (XML format)

Naming Conventions

NC Axis Configuration

1. •Add NC Configuration → Axes → Axis 1
2. •Set engineering units: mm / mm/s / mm/s²
3. •Configure software limits:
   • •Calibration mode: [-50, 4250] mm (allow overshoot)
   • •Production mode: [0, 4200] mm or [10, 4190] mm
4. •Link to E1 drive PDO objects

Extension Libraries

SPT-Libraries (Beckhoff USA Community)

GitHub: Beckhoff-USA-Community/SPT-Libraries

Features:

• •Utility function blocks
• •State machine templates
• •Diagnostic tools

Loupe Team Frameworks

GitHub: loupeteam/

Relevant repositories:

• •StarterAsProject - Project template
• •CSVFileLib - CSV file operations
• •Omniverse_Beckhoff_Bridge - Isaac Sim integration

Installation

Use LPM (Loupe Package Manager) or manual import:

1. •Download library files
2. •TwinCAT → PLC → References → Add Library
3. •Install to Library Repository if needed

State Machine Pattern (ST)

Recommended Structure

TYPE E_MachineState :
(
    ST_IDLE,
    ST_INIT,
    ST_RUNNING,
    ST_ERROR,
    ST_STOPPING
);
END_TYPE

FUNCTION_BLOCK FB_StateMachine
VAR
    eState      : E_MachineState := ST_IDLE;
    eStatePrev  : E_MachineState;
    bStateEntry : BOOL;
END_VAR

// State entry detection
bStateEntry := (eState <> eStatePrev);
eStatePrev := eState;

CASE eState OF
    ST_IDLE:
        IF bStateEntry THEN
            // Entry actions
        END_IF
        // State logic

    ST_INIT:
        // ...

    ST_ERROR:
        // Error handling

END_CASE

Motion FB Usage (PLCopen)

VAR
    fbPower     : MC_Power;
    fbReset     : MC_Reset;
    fbMoveVel   : MC_MoveVelocity;
    fbStop      : MC_Stop;
    fbSetPos    : MC_SetPosition;
    Axis        : AXIS_REF;
END_VAR

// Power on
fbPower(Axis := Axis, Enable := TRUE);

// Move with velocity
fbMoveVel(
    Axis := Axis,
    Execute := TRUE,
    Velocity := 1000.0,  // mm/s
    Acceleration := 5000.0,
    Deceleration := 5000.0
);

// Stop
fbStop(Axis := Axis, Execute := TRUE, Deceleration := 5000.0);

Homing Sequence State Machine

For incremental encoder systems (power-up calibration required):

TYPE E_HomeScanState :
(
    ST_IDLE,
    ST_WAIT_SAFE,
    ST_RESET_FAULT,
    ST_POWER_ON,
    ST_SET_SAFE_LIMITS,
    ST_MOVE_TO_NEG_LIM,
    ST_STOP_AT_NEG_LIM,
    ST_SEEK_HOME_FROM_NEG,
    ST_SET_HOME_POS,
    ST_MOVE_TO_POS_LIM,
    ST_STOP_AT_POS_LIM,
    ST_RETURN_HOME,
    ST_DONE,
    ST_ERROR,
    ST_ABORT_STOP
);
END_TYPE

Calibration Flow

1. •Move to Negative Limit (low speed, 100-300 mm/s)
2. •Seek Home from Negative (set position to 0.0 mm)
3. •Move to Positive Limit (verify full travel)
4. •Return to Home (verify repeatability)

Offline Development

Local Simulation (No Hardware)

1. •Create project without scanning real devices
2. •Add simulated axis: NC Configuration → Add Simulated Axis
3. •Set target system to local (127.0.0.1.1.1)
4. •Activate configuration and run

Remote Connection to C6030

1. •Add route to C6030 (via AMS Router)
2. •Set target system to C6030 AMS NetId
3. •Use Remote Manager if version mismatch

Task Configuration

Recommended Settings

DC Synchronization

Ensure PlcTask and NcTask cycles match EtherCAT DC Sync0 period.

Debugging Tips

Watch Variables

• •Axis.NcToPlc.ActPos - Actual position
• •Axis.NcToPlc.ActVelo - Actual velocity
• •Axis.NcToPlc.StateDWord - Axis state bits
• •Axis.Status.Error - Error flag

Common Issues

Available References

• •references/project-evaluation.md - TwinCAT project evaluation report for LMSA13L
• •references/solution-requirements.md - Complete TwinCAT solution requirements
• •references/beckhoff-tutorial.md - Beckhoff Taiwan EtherCAT tutorial notes
• •references/extension-libraries.md - Extension library descriptions
• •references/spt-libraries.md - SPT-Libraries (Beckhoff USA Community) details
• •references/csvfilelib.md - CSVFileLib (Loupe Team) documentation
• •references/github-repos-analysis.md - Analysis of Loupe Team and Beckhoff USA GitHub repos